The development of microstructures which combine high
total surface
area and high porosity is crucial for technologies such as electrocatalysis,
electrochromics, and sensors. High deposition rate, composition control
of deposition, and low processing temperature to retain active compositions
are also desirable. To this end, this study describes combining colloidal
sol chemistry with a nonthermal atmospheric pressure dielectric barrier
discharge plasma jet to print hybrid inorganic/organic tungsten trioxide/oxalic
acid (WO3–x
/OA) microspheres. Injection
of an aerosol of oxalic acid stabilized colloidal tungstic acid into
an atmospheric pressure plasma jet results in the deposition of spherical
structures in which the colloid is trapped within a plasma-polymerized
organic shell. Subsequent low-temperature sintering produces hierarchical
spherical shell-like structures comprising tungsten oxide nanosheets.
Alteration of the gas flow rate changes the composition of the deposited
material. The method has promise for the general preparation from
colloidal precursors of porous materials of controlled morphology
and composition with hierarchical microstructures, such as are required
for applications in electrochemical devices and sensors which need
a high ratio of surface area to volume and connectivity throughout
the structure, yet also need a microstructure which is open for rapid
exchange of reactants.